Polaris 800 Big Boss manual

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For your nearest Polaris dealer , call 1-800-POLARIS or visit www .polarisindustries.com Polaris Sales Inc., 2100 Hwy . 55, Medina, MN 55340 Phone 1-888-704-5290 Part No. 9922027 Rev 02 Printed in USA[...]

W A RNING The engine exhaust from th is product contains chemicals known to the Stat e of California to cause cancer , birth defects or other reproductive harm.[...]

1 WELCOME Thank you for purchasin g a Polaris vehicl e, an d welcome to our world- wide family of Polaris owners. W e proudly produce an exciting line o f utility and recreati onal products. • Snowmobiles • All-terrain vehicles (A TVs) • RANGER utility vehicles • V ictory motorcycles W e believe Polaris sets a standard of excellence for a l[...]

2 POLARIS and POLARIS TH E W A Y OUT are registered t rademarks of Polaris Indus- tries Inc. Copyright 2008 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of publication. Due to constant improvements in the design and quality of production components, some minor discrep-[...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Features and Controls . . . . . . . . . . . . . . . . . . . 26 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Emission Control Systems . . . . . . . . . . . . [...]

4 INTRODUCTION The following signal words and symbol s appear throughout th is manual and on your vehicle. Y ou r safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symb ol indicates a potential personal injury ha zard. W ARN ING A W ARNING indicates a hazardou[...]

5 INTRODUCTION Failure to heed the warnings and safety precautions contained in thi s manual can result in severe injury or death. This Polaris vehicle is not a toy and can be hazardous to operate. Thi s vehicle handles differently than other vehicle s, such as motorcycles and cars. A collision or rollover can occur quickly , even during routine ma[...]

6 INTRODUCTION V ehicle Identification Numbers Record your vehicle's identificatio n numbers and key numb er in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using your k e y number) and mating it with one of yo ur existing keys. The ignition swit[...]

7 SAFETY Safety T raining Safety training is a top p riority for Polaris. When you purchased your new vehicle, your dealer i nstru cted you o n the authorized A TV Rider- Course sm available to you and your eligib le family members. This train- ing is included in the purchase price of your vehicle. Polaris strongly encourages you and your eligible [...]

8 SAFETY Safe Riding Gear Always wear appropriate clothing when riding this vehicle. W ear pro- tective clothing for comfort and to reduce the chance of injury . Helmet W earing a helmet can prevent a sever e head injury . Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in[...]

9 SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever riding a Polaris vehicle, always wear shatterproof goggles o r use a shatterproof helmet face shield. Po laris recommends wearing approved Personal Prot ective Equi pment (PPE) bearing markings such as VESC 8, V -8, Z87.1, or CE. Make s[...]

10 SAFETY Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result i n serious injury or death. Heed all safety warnings outlined in this section of the owner ’ s manu al. See the OPERA TION section of the owner ’s manual for proper operating proce dures. Operating Without Instru[...]

11 SAFETY Safety W arnings Handling Gasoline Gasoline is highl y flammable and explosive u nder certain conditions. • Always exercise extreme caution w henever handling gasoli ne. • Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or near the area where refu- el[...]

12 SAFETY Safety W arnings Protective App arel Riding in this vehicle without wea ring an approved helmet and protective eyewear increases the risk of a seri ous injuries in the event of an accident. Operator and passenger must always wear an approved helmet that fits properly and eye protection (goggles or face shield). Using Alcohol or Drugs Oper[...]

13 SAFETY Safety W arnings Operating on Pavement Operating this vehicle on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the vehicle and could result in loss of control and accident or overturn. Avoid operating the vehicle on pavement. The tires are designed for off-road use. If it&apos[...]

14 SAFETY Safety W arnings Physical Control of the V ehicle Removing a hand from the handlebars or feet from the footrests during operatio n can reduce your abili ty to control th e vehicle or cause loss of balance and ejection from the vehicle. If the operator's foot is not firmly planted on the footrest, it could also contact the rear wheels[...]

15 SAFETY Safety W arnings Descending Hill s Improper ly Improperly descending a hill could cause loss of control or overtu rn. • Always follow proper procedures for travel- ing down hi ll s as de scri b ed in the owner's manual. NOTE: A special technique i s required when braking while traveling down- hill. See page 57. • Always descend a[...]

16 SAFETY Safety W arnings St alling While Climbing a Hill S talling, rolling backwards or improperl y dismounting while climbing a hil l could cause an overturn. • Always maintain a steady speed whe n climbing a hill. • Always move the 4X4 switch to ADC 4X4 (if equipped) before ascending or desce ndi ng a hill. See page 36. If all forward spee[...]

17 SAFETY Safety W arnings Operating on Steep Hills Operating on exce ssively steep hills co uld cause an overturn. Never operate on hills too steep for the vehicle or for your abilities. Never operate the veh icle on hills steeper than 25 degrees. Operating on Slippery T errain Failure to use extra caution when operati ng on excessively rough, sli[...]

18 SAFETY Safety W arnings Improper Tire Maintenance Operating this vehicle with improper tires or with impro per or uneven tire pressure could cause loss of control or accident. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure as described in the owner's manual and on safety labels. Operat[...]

19 SAFETY Safety W arnings Improper Cargo Loading Overloading the vehicl e or carryi ng/towing cargo improperly may cause changes in handling, which could cause loss of control or an accident. • Never exceed the stated load capacity for this vehicle. • Cargo should be p roperly distrib uted and securely attached. • Reduce speed when carrying [...]

20 SAFETY Safety W arnings Operating Through Deep W ater Operating the vehicle through deep o r fast-flowing water could cause the ti res to float, causing loss of control or overturn. Avoid operating the vehicle throu gh deep or fast-flowing water . If it's unavoidable to enter water that exceeds the recommended maximum depth (see page 59): ?[...]

21 SAFETY Safety W arnings Operating a Damaged V ehicle Operating a damaged vehicle can result in an acciden t. After any overturn or accident, have a qualifi ed service dealer inspect the entire ma chine for possible damage, including (but not limited to) brakes, th rottle and steering systems. Physical Skills Safe operation of this rider-active v[...]

22 SAFETY Safety Labels and Locations W arn ing labels have been plac ed on the vehicle for your protectio n. Read and follow the instructions of the labels on the vehicle carefully . If any of the labels depicted in this ma nual dif fer from the labels on your vehicle, always re ad and follow the instructions of the labels on the vehicle. If an in[...]

23 SAFETY Safety Labels and Locations Tire Pressure/Load W arning W ARNING Improper tire pressure or overlo ading can cause loss of co ntrol. Loss of control can result in severe injury or death. • Cold tire pressure: Front: 7.0 psi (48.3 kPa) Center: 10.0 psi (68.9 kPa) Rear: 10.0 psi (68.9 kPa) • Maximum weight capaci ty: 1 1 15 lbs. (507 kg)[...]

24 SAFETY Safety Labels and Locations Cont ainer/No Passenger Warning W ARNIN G Remove flammable containers from box before refueling. W ARNIN G • Passengers can be thrown off. This can cause serious injury or death. • Never carry passengers. Maximum Box Load 800 lbs. (363 kg) 7079316 + Clutch Cover Wa r n i n g + Age 16 W arn in g + Container/[...]

25 SAFETY Safety Labels and Locations Age 16 W arning W ARNING Operating this A TV if you are unde r the age of 16 increases your chance of severe injury or death. NEVER operate this A TV if you are under age 16. 7172588 Clutch Cover W arning W ARNING • Moving parts hazard under belt-clutch gu ard. T o p revent serious injury , do not operate veh[...]

26 FEA TURES AND CONTROLS Switches Mode/Reverse Override Switch This vehicle is equipped with a re verse speed limi ter sy s t em .T o gain additional wheel speed while backing, release the throttle and depress the override button. W ARNING! Pressing the override button while the thro ttle is ope n can cause loss of control, which may result in ser[...]

27 FEA TURES AND CONTROLS Switches Engine Stop Switch Move the stop switch either left or right to the OFF position to stop the engine quickly . The engine will not start or run when the switch is off. Both the main switch and the engine stop switch will shut of f all electri- cal power to the vehicle, including lights. Main Key Switch Use the main[...]

28 FEA TURES AND CONTROLS Throttle Lever Operating this vehicle with sticking or improperly operatin g throttle controls could cause an accident. Never start or ope rate the vehicle if it has a sticking or improperly operating throttle . Always c ontact your dealer for service before operating the vehicle. Failure to check or maintain proper operat[...]

29 FEA TURES AND CONTROLS Brake Systems Aggressively applying the rear brake wh en backing down a hill may cause rear tipover , which could result in seriou s injury or death. N ever back down a hill. Use caution when ap plying the rear brake. Do not aggressivel y apply the rear brake when going forward. The rear wheels may skid and sli de sideways[...]

30 FEA TURES AND CONTROLS Brake Systems Service Brake Lever Squeeze the service brake lever (left lever) toward the handlebar to apply the front and rear brakes. These brakes are hydraulically acti- vated disc brake s. Always test brake lever travel and master cylinder fluid level before riding. When squeezed, the lever should feel firm. Any spongi[...]

31 FEA TURES AND CONTROLS Master Cylinde r/Brake Fluid An over-full master cyl inder may cause brake drag or brake l ock-up, which could result in an accident. Maintain brake fluid at the recommended level. Do not overfill. Never store or use a partial bottle of br ake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the [...]

32 FEA TURES AND CONTROLS Parking Brake Locking the Parking Brake 1. Place the transmission in park. 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock forward to engage the lock. 4. Release the brake lever . 5. T o release the parking brake lock, squeeze and release the brake lever . It[...]

33 FEA TURES AND CONTROLS Automatic T ransmission Gear Selector The transmission gear selector is located on the right side of the vehicle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park T o shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear . NOTICE: Shifting gears with the engin e speed ab[...]

34 FEA TURES AND CONTROLS All Wheel Dri ve (A WD) System The All Wheel Drive syst em is controlled by the 4X4 (A WD) switch. ADC 4X4 Mode (if equipped) When the switch is on ADC 4X4, the ADC system allows engine braking to all six wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descendin[...]

35 FEA TURES AND CONTROLS All Wheel Drive System Engaging A WD The 4X4 switch may be turned on or off while the vehicle is movin g. Initially , the vehicle's electronic sy stem will not enable A WD until the engine RPM is below 310 0. Once en abled, A WD remain s enabled until the 4X4 switch is turned off. If the switch is turn ed of f while t[...]

36 FEA TURES AND CONTROLS Active Descent Cont rol (ADC) System The ADC sys tem (if eq uippe d) allows engi ne braking to all fou r wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascen ding or descending a hill. Engaging Active Descent Control The ADC system will auto matically engage when all four o[...]

37 FEA TURES AND CONTROLS Instrument Cluster Y our vehicle is equipped with an instrument cluster that senses vehicle speed from the right front wheel. In addition to showing vehicle speed, the speedometer needle flashes when a warning condition exists. The instrument cluster measures distance in miles as well as hours of operation. It also include[...]

38 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster . All seg- ments will light up for 2.5 seconds at start-up. If the instrument cluster fails to illuminate, a battery over - voltage may have occurred and the instrument cluster ma y have shut of f to protect the el[...]

39 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center St andard Modes Use the MODE button to toggle thro ug h the mode options. The reverse override button is also the MODE bu tton. See page 26. The transmis sion cannot be in reverse wh en using this feature. Odometer Mode The odomete r records the miles travel ed by the vehicle. T [...]

40 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when th e gauge is in the diagnostic mode. T o exit the diagnostic mode, turn th e key switch of f and on. Any move- ment of the tires will also cause the gauge to exit the diagnostic mode. T o enter the diagnostics mode: 1. T urn the [...]

41 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery V oltage Screen V iew this screen to check battery voltage level. T achometer Screen V iew the tachometer to check engine speed. 4X4 Diagnostic Screen The gauge ind icates whether or not current is flowing through the all- wheel-drive coil. This screen is [...]

42 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval T o enable or disable the service interval: 1. Enter the diagnostic mode. 2. T oggle to the service interval screen. 3. Press and hold the mode button for about 7 seconds, until either ON or OFF appears in the Rider Information Center[...]

43 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes The EFI diagnostic mode is for informational purp oses only . Please see your Polaris dealer fo r all major repairs. See page 45 for Blink Co des and Failu re Descriptions. Use the follow- ing procedure to downlo ad blink codes (failure codes) from the EFI modul[...]

44 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Code Definitions Open Load: There is a break in the wires that lead to the item listed in the chart (inj ector , fuel pump, etc.), or the item has failed. Short-to-Ground: The wire is shorted to ground between the electronic control unit and the item listed in t[...]

45 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Blink Code F ailure Descript ion 12 BEGIN SEQUENCE 22 Throttle Position Sensor Low 22 Throttle Position Sensor High 22 Throttle Position Sensor Out of Adjustment 25 Gear Sensor Signal 31 System V oltage Low 31 System V oltage High 36 Ignition Coil A Prim/Sec Cir[...]

46 OPERA TION Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Rea d and understand all safety warnings outlined in the safety section of this owner ’s manual. Break-In Period The break-in period for your new P olaris vehicle is the first ten hou[...]

47 OPERA TION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 33. Always exercise extreme caution whenever handling gasoline. 2. Check the engine oil level on the dipstick. See page 72. Add oil if necessary to maintain the level between the safe and add marks. 3. Drive slowly at first. Select an op en ar[...]

48 OPERA TION Pre-Ride Checklist Failure to inspect and verify that th e vehicle is in safe operating condi- tion before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition. Item Remarks Page Brake system/lever travel Ensure proper operation 29 84 Brake fluid Ens[...]

49 OPERA TION Safe Operation Practices 1. Complete the recommen ded safety training before operatin g this vehicle. See page 7. 2. Do not allow anyone und er 16 year s of age to operate this vehicle. Do not allow anyone w ith cognitive or physical disabi lities to oper- ate this ve hicle. 3. Never carry a passe nger on this vehic le. 4. Engine exha[...]

50 OPERA TION Know Y our Riding Area/T read Lightly Familiarize yourself with all laws and regulations concerning the opera- tion of this of f-road vehicle in your area. Respect the environment in which you ride. Fin d out where the de signated riding areas are by con- tacting your Polaris dealer , a local rid ing club or local officials. Help keep[...]

51 OPERA TION S tarting the Engine 1. Position the vehicle on a level su rface outdoors or in a well-venti- lated area. 2. Place the transmission in park. 3. Lock the parking brake. Tip : The starter interlock will prevent the eng ine from starting if the transmission is in gear and the brake is not engaged. 4. Sit on the vehicle and move the engin[...]

52 OPERA TION Driving Procedures 1. W ea r a helmet and eye protection. See page 8. 2. Sit upright with both feet on th e footrests and both hands on the handlebars. 3. Star t the engine and allow it to warm up. 4. Shift the transmission into gear . 5. Check your surroun dings and determine your path of travel. 6. Release the parking brake. 7. Slow[...]

53 OPERA TION T urning the V ehicle Y our vehicle is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turn- ing and the inside tire must slip traction slightly . T o turn, steer in the direction of the t[...]

54 OPERA TION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather , follow these precautions: 1. Do not operate on excessively ro ugh, slippery or loose terrain. 2. Slow down when entering slippery areas. 3. Engage 4X4 before whee ls begin to lose traction. NOTICE: Severe [...]

55 OPERA TION Driving Uphill Braking and handling are greatly affe cted when operating in hilly ter- rain. Improper pro cedure could cau se loss of control or overturn. When- ever traveling uphill, fo llow these precautions: 1. Always move the 4X4 switch to ADC 4X4 (if equipped) before ascending or descending a hill. See page 36. 2. Drive straight [...]

56 OPERA TION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not reco mmended. Improper procedure could cause loss of control or overturn. A v oid crossing the side of any hill unless absolutely ne cessary . If crossing a sidehill is unavoidable , follow these precautions: 1. Slow down. 2. A void crossing the side of a steep hill. 3. [...]

57 OPERA TION Driving Downhill When driving downhill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 (if equipped) before ascending or descending a hill. See page 36. 2. A void steep hills (25 ° maximum). 3. Shift body weight uphill. 4. Drive straight downhill. 5. Slow down. Excessive speed wh en traveling downhill can cause lo[...]

58 OPERA TION T urning Around on a Hill (K-T urn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 1. S top and lock the parking brake while keeping body weight up hill. 2. Always move the 4X4 switch to ADC 4X4 (if equipped) before ascending or descending a hill. See page 36. 3. Leave the tran[...]

59 OPERA TION Driving Through W ater Y our vehicle can operate through water with a maximum recommended de pth equal to the bottom of the footrests. Fol- low these procedures w hen operating through water: 1. Determine water depths and current before entering water . 2. Choose a crossing where both banks have grad ual inclines. 3. A void operating [...]

60 OPERA TION Driving Over Obst acles Follow these precautions whe n operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for haz- ards such as logs, rocks and low hanging branches. 3. T ravel slowly and use extra cau tion when operating on unfamilia[...]

61 OPERA TION Driving in Reverse Follow these precautions w hen operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid backing downhill. 3. Back slowly . 4. Apply the brake s lightly for stopping. 5. A void turning at sharp angles. 6. Never open the throttle suddenly . 7. Do not use the override button unl[...]

62 OPERA TION Hauling Cargo Overloading the vehicl e or carrying or to wing cargo imp roperly can alte r vehicle handling and may cause loss of control or brake instability , which can result in serious injury or death. Always follo w these precaution s when hauling cargo: • Never exceed the maximum weight capacity of the vehicle. Whe n determini[...]

63 OPERA TION Hauling Cargo 1. Always read and understand th e load distribution warning labels on the vehicle, and never exceed the weight capacities outlined in the specifications section of the owne r's manual and on the safety labels. The total load (operator , accessories, cargo and weight on hitch) must not exceed the maximum weight capa[...]

64 OPERA TION Hauling Cargo Dumping Cargo 1. Select a level site to dump the cargo. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Lock the parking brake. 3. Dismount the vehicle. 4. Check car go distribution. If car go has shifted to the rear of the box, exercise caution. W ARNING! If the weight distribution in the box[...]

65 OPERA TION Parking on an Incline A void parking on an incline if poss ible. If it's unavoidable, follow these precautions: 1. S top the engine. 2. Place the transmission in park. 3. Lock the parking brake. 4. Always block the rear wheels on th e downhill side.[...]

66 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EP A noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Y our Polaris vehicle has a spark arrestor that was tested and qualif[...]

67 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic main ten a nc e ch art. Inspect, clean, lubricate, adjust and replace parts as necessary . When inspection reveals the[...]

68 MAINTENANCE Periodic Maintenance Chart Improperly performing the p rocedures marked with a  could re sult in component failure and ca use an accident, which may result in seri ous injury or death. Always have an authorized Pola ris de aler perform these services. Maintenance Chart Key X Perform these operations more often for vehic les subjec[...]

69 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) X E Air filter , main element - Weekly - Inspect; replace as needed X Q Brake pad wear 10 H Monthly 60 (100) Inspect periodically X Engine oil change (break-in) 20 H 1 M 125 (200) Per form a break-in oil change Battery 20 H [...]

70 MAINTENANCE Periodic Maintenance Chart X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service  Have an authorized Polaris dealer perform these services. Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) X Engine oil change 100 H 6 M 620 (1000) Perform a break-i[...]

71 MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Ch art beginning on page 67. Items not listed in the chart should be lubricated at the General Lubrication interval. The a-arms and lower control arms are lubricated at the factory , and no additional lubrication wil[...]

72 MAINTENANCE Engine Oil Oil Recommendations Polaris recommends the use of Polaris PS-4 PLUS Performance Syn- thetic 2W -50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if Polari s oil is not used. Always use 2W -50 oil. Follow the manufacturer's re commendations fo r ambient tempera- ture operation[...]

73 MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at th e intervals outlined in the Periodic Maintenance Chart beginning on page 67. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface. 2. Star t the engine. Allow it to warm up at idle for two to three minutes. Stop the engin[...]

74 MAINTENANCE Engine Oil Oil and Filter Change 10. Lubricate the o-ring on the new filte r with a film of fresh engine oil. Check to make sure the o -ring is in good condition. 1 1. Install the new filter and rotate it clockwise by hand until the filter gasket contacts the sealing surface, then turn it an additional 1/2 turn. 12. Remove the dipsti[...]

75 MAINTENANCE T ransmission Oil Always check and change the transmission oil at the interval s outlined in the Periodic Mainte- nance Chart beginning on page 67 . Maintain the oil le vel at the bottom of the fill plug hole. The fill plug is located on the right side of the A T V beh ind the footwell. The drain plug is located on the bottom left si[...]

76 MAINTENANCE Front Gearcase (Dem and Drive) Fluid Always check and change the demand drive fluid at the intervals out- lined in the Periodic Maintenance Ch art beginning on page 67. W e rec- ommend the use of Demand Drive L T Premium Fluid . Use of other fluids may result in improper operation of components. See page 124 for the part numbers of P[...]

77 MAINTENANCE Front Gearcase (Dem and Drive) Fluid Fluid Change 1. Position the vehicle on a level surface. Remove the fill plug. 2. Place a drain pan under the demand drive unit. 3. Remove the drain plug. Allow the fluid to drain completely . 4. Clean and reinstall the drain plug . T orque to 1 1 ft. lbs. (15 Nm). 5. Add the recommend ed fluid. 6[...]

78 MAINTENANCE Rear Gearcase Oil Always check and change the rear gearcase oil at the in tervals outlined in the Periodic Maintenance Chart beginning on page 67. Maintain th e fluid level at the bottom of the fill hole threads. The oil capacity is 5 oz. (150 ml). Do not overfill. The fill plug is located on the rear of the gearcase. The drain plug [...]

79 MAINTENANCE Middle Gearcase Oil Always check and change the mid- dle gearcase oil at the intervals outlined in the Periodic Mainte- nance Chart begin ning on page 67. W e rec ommend the use of Pola ris A TV Angle Drive Fluid (or GL5 80-90 weight gear lube). See page 124 for the part numbers of Po laris products. The middle gearcase fill plug is [...]

80 MAINTENANCE Active Descent Control (ADC) Fluid If your vehicl e is equipped with Ac tive Descent Control, there are two fluid levels that must be mainta ined (demand drive fl uid and ADC fluid). See page 76 for dema nd drive fluid maintena nce. Check and change the ADC fluid level at the intervals outlined in the Periodic Maintenance Chart begin[...]

81 MAINTENANCE Active Descent Control (ADC) Fluid Fluid Change 1. Position the vehicle on a level su rface. Before performing the fluid change, allow the vehicle to sit for at least 30 minutes. 2. Thoroughly clean the areas around and on the ADC reservoir and bleeder valves (one on each side of the differential). 3. Remove the reservoir cap and dia[...]

82 MAINTENANCE Cooling System The engine coolant level is controlled, or maintained, by the recovery system. The recovery system compon ents are the reco very bottle, the radiator filler neck, the radiator pressure cap and the connecting hose. As coolant operating temperature increases, the expa nding (hea ted) excess coolant is forced out of the e[...]

83 MAINTENANCE Cooling System Radiator Coolant T o ensure that the coolant maintain s its ability to protect the engine, Polaris recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water . Replace the coolant any time the coo ling system has been drained for maintenance or repair . If the recove[...]

84 MAINTENANCE Brakes Front/Rear/Middle Brakes The front, rear and middle brakes are hydraulic disc brakes. These brakes are self-adjusting. Under normal operation, the diaphr agm extends into the reservoir as fluid level drops. If the fluid le ve l is low and the diaphragm is not extended, a leak is likely and the dia phragm should be repla ced. T[...]

85 MAINTENANCE T oe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alig nment is 1/8" to 1/4" (3-6 mm) toe out. W ARNING! Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adju st tie rod alignment. All tie rod a djustments should be perfor[...]

86 MAINTENANCE S teering Assembly The steering as sembl y of the vehicle should be checked periodically for loose nuts and bolts. If loose nu ts and bolts are found, see your Polaris dealer for service before operati ng the vehicle. Side Panel Re moval 1. Remove the seat. 2. Grasp the rear of the side panel near the rear cab. With a firm motion, pu[...]

87 MAINTENANCE Ti r es Operating your vehicle with worn tires, i mproperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling an d could cause an accident resulting in serious injury or death. Alwa ys follo w all tire maintenance procedures as outlined in this manual a nd on the labels on the vehicle. Al w[...]

88 MAINTENANCE Ti r es Wheel Inst allatio n 1. Place the transmission in park. 2. Lock the parking brake. 3. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing t o ward forward rotation. 4. Install the wheel nuts and finger-tighten them. 5. Lower the vehicle to the ground. 6. T orque the wheel[...]

89 MAINTENANCE Air Filter 1. Remove the seat. 2. Release the air box cover clips, and remove the air box cover . 3. Loosen the clamp and remove the filter . 4. Remove the fabric type pre-filter from the main filter . W ash the pre-filter in soapy water , then rinse and let dry . 5. Reinstall the pre-filter over the main filter . Install a new main [...]

90 MAINTENANCE Fuse Replacement If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replace- ment. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. Spare fuses are provided in a com- partment on the top of the access door . 1. Open the front box cov [...]

91 MAINTENANCE Light s Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty duri ng normal operation. Clean lights frequently and replace burn ed out lamps promptly . Always make sure lights are adjusted properly for best visibility . Upper Headlight Lamp Replacement When servicing a halog en lamp[...]

92 MAINTENANCE Light s High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 1. Position the vehicle on a level su rface with the headlight approxi- mately 25 ft. (7.6 m) from a wall . Place the transmission in park. 2. Measure the distance from the floo r to the cen[...]

93 MAINTENANCE Light s Low Beam Adjustment The low beam can be adjusted slightly upward or do wnward. 1. Loosen the phillips screw located at the rear o f the headlamp. 2. T ilt the headlamp upward or downward. 3. T ighten the screw . Phillips Screw[...]

94 MAINTENANCE Light s Headlight Housin g Replacement 1. Remove the two screws on the lowe r front corners of the headlight pod. 2. Lift the pod slightly while depressing the tabs at the rear of the pod. 3. Lift the pod cover and disconn ect the speedometer harnes ses from the speedometer . 4. Unplug the headlamp from the wiring harness. 5. Use a s[...]

95 MAINTENANCE Light s Lower Headlamp Replacement 1. T urn the back of the headlight harness counterclockwise and pull the harness assembly away from the headlight assembly . 2. Remove the head lamp and install the new headlamp . 3. Reinstall the harness assembly into the headlight assembly . 4. T urn the headlight harness clock- wise to secure the[...]

96 MAINTENANCE Spar k P l u g s Sp ark Plug Recommendatio ns Refer to the specifications sect ion beg inn ing on pa ge 1 22 for the recom- mended spark plug t ype and gap for yo ur vehicle. T orque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs.[...]

97 MAINTENANCE Spar k P l u g s Sp ark Plug Insp ection Normal Sp ark Plug The normal insulator tip is gray , ta n or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service. The tip should not be flaky and wh ite. A white insulator t[...]

98 MAINTENANCE V ehicle Immersion If your vehicle becomes imm ersed, major engine da mage can result if the machine is not thoroughly inspecte d. T ake the vehicle to your dealer before starting the engine. If it's impo ssible to take your vehicle to a dealer before starting it, fo llow the steps outlined below . 1. Move the vehicle to dry lan[...]

99 MAINTENANCE S park Arrestor Failure to heed the following warnings whil e servicing the spark arrestor could result in serious injury or death. Ne ver run the engine in an enclosed area. Remove any combustible materials from the area. Wear eye protectio n and leather work gloves. Do not stand behind or in fro nt of the vehicle while purging. Nev[...]

100 MAINTENANCE P V T System Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a hig h speed. The PVT system has been precision balanced. Any modi fication will cause the system to be out of bala[...]

101 MAINTENANCE P V T System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requiremen ts. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases th e amount of pinch applied to the drive belt. Similarly , if the engine speed [...]

102 MAINTENANCE P V T System When T o Use Low Range and High Range PVT Drying There may be some instances when wate r is accidently ingested into the PVT system. Use the following instructions to dry it out before operat- ing. 1. Position the vehicle on a level surface. 2. Remove the drain plug. Allow the water to drain completely . Rein- stall the[...]

103 MAINTENANCE Battery Improperly connecting or disconnecting battery ca bles can result in an explosio n and cause serious injury or death. When removing the battery , always disconnect the negative (black) cable first. When reinstalling the battery , a lways connect the negative (black) cable last. Battery electrolyte is poisonous. It contains s[...]

104 MAINTENANCE Battery Battery Removal 1. Remove the seat. 2. Disconnect the battery hold-down strap. 3. On conventional batteries, re move the battery vent tube. 4. Disconnect the black (negative) battery cable first. 5. Disconnect the red (positive) battery cable last. 6. Lift the battery out of the ve hicl e. Be careful not to tip a conven- tio[...]

105 MAINTENANCE Battery Battery Inst allation Using a new battery that has not been fully char ged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructio ns on page 107 before installing the battery . 1. Ensure that the battery is fully char ged. 2. Place the battery in [...]

106 MAINTENANCE Battery Battery S torage Whenever the vehicle is not used for a period of three mo nths or more, remove the battery from the vehicle, ensure that it's fully char ge d, and store it out of the sun in a cool, dry place. Check battery voltage each month during storag e an d recharge as needed to mainta in a full charge. Polaris re[...]

107 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to prevent damage from leak- ing or spilled electroly t e du ring charging. See page 104. 2. Charge the battery with a char ging output no larger than 1/10 of the battery’ s amp/hr rating. Charge as needed to raise the spec ific grav- ity to 1.[...]

108 MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition befo re and 1-2 hours after the end of charging. St ate of Charge V oltage Action Charge Time (Using constant current charger @ standa rd amps specifie d on to p o f ba t t er y) 100% 12.8-13.0 volts None, check at 3 mos. from date of manufacture None required[...]

109 MAINTENANCE Cleaning and St orage W ashing the V ehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various comp onents. NOTICE: High water pressure may damage comp onents. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap. Certain products, inclu[...]

110 MAINTENANCE Cleaning and St orage W ashing the V ehicle If a high pressure water system is u sed for cleaning (not recommended), exercise extreme caution. The wate r may damage components and could remove paint and decals. A void direc ting the water stream at the follow- ing items: If an informational or graphic label becomes illegible or come[...]

111 MAINTENANCE Cleaning and St orage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a "like new" appearance for many years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned. Cle[...]

112 MAINTENANCE Cleaning and St orage Sto r ag e Tips NOTICE: S tarting the engine during the storage period will disturb the protective film created by fogging and damage could occur . Never start the engine during the storage peri od. Clean the Exterior Make any necessary repairs and then clean the vehic le as recommended. See page 109. St abiliz[...]

113 MAINTENANCE Cleaning and St orage Sto r ag e Tips Fluid Levels Inspect the following fluid levels. Ch ange fluids as r ecommended in the Periodic Maintenance Char t beginning on page 67. • Demand drive unit (front gearcase) • ADC fluid (ADC models) (change every two years) • Rear gearcase • Middle g earcase • T ransmission • Brake f[...]

114 MAINTENANCE Cleaning and St orage Sto r ag e Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 67. Battery Maintenance Remove the battery and rechar ge it as outlined on page 107. S tore the battery in a cool, dry place. Storage Area/Covers Set[...]

115 MAINTENANCE T ransporting the V ehicle Follow these procedures when transporting the vehicle. 1. S top the engine. 2. Place the transmission in park. 3. Lock the parking brake. 4. Secure the fuel cap, oil cap and seat. 5. Always tie the frame of the vehicle to the transporting unit securely with suitable straps or rope. Do no t attach tie strap[...]

116 ADJUSTMENTS Camber and Caster The camber and caster are non-adjustable. Rear Springs The rear shock absorber springs are adjusted by rotating the adjusters either clockwise or counterclockwise to increase or decrease spring tension. Always adjust all rear springs to equal settings. Accessory springs are available through your Polaris dealer . H[...]

117 ADJUSTMENTS Throttle Body/Idle RPM Idle RPM is preset by the manufactur er . If the engine idle speed is not satisfactory , please see your Pola ris dealer for adjustment. Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar . 1. Locate the throttle cable adjuster at the handlebar . 2. Squeeze the end of the rub- ber boot and[...]

118 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range during loading. Starting out going up a steep incl ine Use low range or turn around using the K-turn (see page 58). Driving at low RPM or ground speed (3-7 MPH) Drive at a higher sp eed or us e low range more frequently[...]

119 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , Fails to St art Engine Backfires Possible Cause Solution Low battery voltage Recharge th e battery to 12.8 VDC Loose battery connections Chec k all connections and tighten Loose solenoid connections Chec k all connections and tighten Possible Cause Solution Out of fuel Refuel, [...]

120 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularl y , St alls or Misfires Possible Cause Solution Poor quality or low octane fu el Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Possible Cause Solution Fouled or defective spark plugs In[...]

121 TROUBLESHOOTING Engine Stop s or Loses Power Engine Overheating Possible Cause Solution Out of fuel Refuel, cycle key to ON position three times for 5 seconds each, then start Kinked or plugged fuel vent line Inspect and replace W ater is present in fuel Replace with new fuel Fouled or defective spark plugs Inspec t, clean and/or replace spark [...]

122 SPECIFICA TIONS * Based on EU Directive 76/432/EC Sport sman Big Boss 6X6 800 EFI Maximum W eight Capacity 1 1 15 lbs. ( 507 kg) (includes operator, car go, accessories) Fuel Capacity 4.1 gal. (15.5 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 3.6 qts. (3.4 l) Demand Drive Fluid Capacity 9.3 oz. (275 ml) Rear Gearcase Oil Capacity 5 o[...]

123 SPECIFICA TIONS Clutching *EBS models require no helix/spring adjustment Sport sman Big Boss 6X6 800 EFI T r ansm ission Automatic PVT with E-Z Shift H/ L/N/R/P Gear Reduction, Low 7.49:1 Gear Reduction, Reverse 5.1 1:1 Gear Reduction, High 3.05:1 Drive Ratio, Front 3.82:1 Drive Ratio, Final 3.10:1 T i res/Pressure, Front 25x8-12 / 7 psi (48.3 [...]

124 POLARIS PRODUCTS Part Number Description Engine Lubr icant 2870791 Fogging Oi l (12 oz. Aerosol) 2876244 PS-4 PLU S Per formance Synthetic 2W -50 4-Cycle Oil (qt.) 2876245 PS-4 PLUS Performan ce Synthetic 2W-50 4-Cycle Oil (gal.) Gearcase / T ransmission Lu bricants 2873602 Premium AGL Synthetic Ge arcase Lubricant (q t./.9 5 l) 2873603 Premium[...]

125 W ARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Me dina, MN 55340, gives a SIX MONTH LIM- ITED W ARRANTY on all components of the Polaris Light Utilit y V ehicle against defects in material or work manship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defect s. This warranty covers t[...]

126 W ARRANTY WARRANTY COVERAGE AND EX CLUSIONS: LIMIT A TIONS OF WARR ANTIES AND REMEDIES The Polaris limi ted warranty excludes any failu res that are not caused by a defect in material or workmanship. Th is warranty does not cover acci dental damage, normal wear and tear , abuse or improper handling. This wa rranty also does not c over any vehic[...]

127 W ARRANTY ALL IMPLIED W ARRANTIES (INCLUDING BUT N OT LIMITED TO THE IMPLIED W ARRANTIES O F MERCHANT ABILITY AND FITNESS FOR A P AR- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE SIX MONTH W ARRANTY PERIOD. POLARIS FUR THER DISCLAIMS ALL EXPRESS W ARRANTIES NOT ST A TED IN THIS W ARRANTY . Some states do not allow limi- tations on how[...]

128 W ARRANTY Exported V ehicles EXCEP T WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER'S AUTHORIZED LOCA - TION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Deal[...]

129 W ARRANTY Exported V ehicles How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, a ll warranty coverage will be denied. Notice If your vehicle is registered outside of the country where it was purchased, and you have [...]

130 W ARRANTY U.S.A. EP A Emissions Limited Warranty This All T errain V ehicle (A TV) or Of f Road Utility V ehicle (ORUV) emissions limited warranty is in additi on to the Polaris st andard limited warrant y for this vehicle. Polaris warrants that this vehi cle is; (1) designed, built, and equipped to conform at the time of initial sale with the [...]

131 MAINTENANCE LOG Present this section of your ma nual to your dealer each ti me you r vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and ser- vices performed. DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

132 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

133 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]